6 juergen himmelmann-energy efficient melt shop operation abp

1. Agenda
 Energy balance for melting iron
 Energy balance of a state of the art
Induction melting system
 State of the are melting system ABP
 Energy balance of a melting system
 Energy effective melt process
 Integration of the melt operation into
the total process
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 Automatic pouring system АВР
 Pouring via OptiPour®
 Energy - Benchmark

2. Energy balance for melting iron
 Enthalpy for melting 1to of iron at 1.500 °C: 396 kWh/t
kWh/t
1.200
1.000
800
Additions
600 Material losses
Gas / oel
electrical Engergy
400
Koke
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200
0
Cupola Cupola Ind. furnace Ind. furnace Rotary
furnace - cold furnace - hot LF MF furnace
wind wind
Source University of Hannover

3. Energy balance for melting iron
 Specific CO2 Emission for melting of one ton iron
gr/t
600
500
400
300
200
100
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0
Cupola furnace Cupola furnace Ind. Furnace Ind. furnace Rotary furnace
- cold wind - hot wind LF MF
 Including the emission of power plans with today's energy mix
Source University of Hannover

4. Agenda
 Energy balance for melting iron
 Energy balance of a state of the art
Induction melting system
 State of the are melting system ABP
 Energy balance of a melting system
 Energy effective melt process
 Integration of the melt operation into
the total process
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 Automatic pouring system АВР
 Pouring via OptiPour®
 Energy - Benchmark

5. Parts of a MF induction furnace system
 Mechanic: Circuit breaker
 Furnace body, lining material Transformer
hydraulic and tilting frame
Cooling system electrics
 Electric: ~ -
 Transformer, Converter MF-
Converter
Capacitor bank, high current -
connection, Coil ~
Capacitor bank
 Control systems:
 Weighing system, Process- Exhaust
Charging system
Control hood
 Auxiliary equipment: Crucible
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furnace Cooling system furnace
 Cooling system, charging
system, exhaust system
Melt processor
Weighing tons
system

6. Latest ABP melting furnaces
Furnace capacity 0,3 … 0,8 t 1t …6t 8 t … 65 t 30 t … 70 t
Type Smart FS FS IFM LFS
Power supply IGBT MF Thyristor Converter
Single Single
Twin Power Twin Power
Power Power
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250 kW – 750 kW –
810 kW – 42.000 kW
500 kW 3.500 kW

7. Comparison between LF and MF
MF LF
Energy consumption 520 - 580 kWh/t 570 – 700 kWh/t
Power density 600 - 1000 kW/t 150 – 300 kW/t
Melt rates 300 % 100 %
Melt conditions Batch type Heel
Flexibility High Low
Changing of alloy Good Bad
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Lining live per molten t High Low
12 т
5т

8. Comparison between LF and MF
MF LF
Melting of chips Low heel High heel
Material density in the High Low
furnace
Maintainance Low, no mechanical High, mechanical switches
wear
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5т 12 т

9. Energy balance of a state of the art induction
melting system
Energy consumption mains  State of the art technology
side 525 kWh/t
 Efficiency:
8 kWh/t losses 80% …75 %
517 kWh/t
transformer  Development tasks
17 kWh/t losses converter  Reduction of coil losses
500 kWh/t
 New lining material
5 kWh/t losses  Reduction of power supply
capacitor bank
495 kWh/t losses
 Reduction of transformer losses
89 kWh/t electrical
losses coil  Aim:
405 kWh/t
 Reduction of installation losses
9 kWh/t thermo
of 60…90 kWh/t
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losses
 Increasing of efficiency to 87%…
396 kWh/t Enthalpy at 1.500 °C 81 %

10. Energy efficient induction furnaces – Coil
losses
Coil losses are app. 70 % of the total
installation losses
 New lining material that covers higher
induction power
 New coil design
 New coil material
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11. Energy efficient induction furnaces –
converter losses
 Today‘s converter losses 3….4 % of the installed power
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 New generation of power electronic components (IGBT, IGCT)
 Improved control systems

12. ABP power supply: IGBT technology
 IGBT = Insulated Gate Bipolar Transistor
 Technical features of IGBTs:
 Rapid switching
 low on- and off switching losses
 low conducting losses
 Rectifier, filter circuit and inverter in a single module with 250 kW or 750
kW, next generation up to 1.500 kW
 Power range: 250 kW – 3.000 kW
 Future up to 6.000 kW
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13. Benefits of IGBT converters
 Modular structure
 using standardized components
 quick and easy maintenance possible
 No de-ionizer water required
 No elements on potential are in direct contact with the cooling water
 Single cooling circuit for the converter and the furnace
 Cos φ always as good as > 0,95
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14. 500 kW converter layout
Control unit
IGBT modules
Coupling choke
Capacitors
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Compact Layout for an easy integration into an
existing plant

15. Agenda
 Energy balance for melting iron
 Energy balance of a state of the art
Induction melting system
 State of the are melting system ABP
 Energy balance of a melting system
 Energy effective melt process
 Integration of the melt operation into
the total process
©ABP Customer day Bangkog, 30.03.2012 15
 Automatic pouring system АВР
 Pouring via OptiPour®
 Energy - Benchmark

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Energy (in) efficient Melt process

17. Energy efficient Melt (foundry) process
 Charge preparation
 Charging
 Melting
 Preparation of the melt
 Furnace emptying
 Metal transport
 Pouring process
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2 ,0t
1 ,5t

18. Energy efficient Melt process –
Charge preparation
Big or small charge material
 The right mix influences the melt time up to 10 min and more
 additional >100 kWh/t
shot blasting of returns
 If returns are not shot blasted they consist a lot of sand
 About 10 % of the returns is sand, that are supplied to the furnace
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 The molten sand creates additional slag
 Example: 10 t scrap with 5 t returns and 10 % sand
 25 kWh/t additional for melting of the sand

19. Energy efficient Melt process –
Charging
 Charging when requested
 Avoiding bridges!
 Process control with melt
processors avoids
interruptions
 Influence of 2 – 4 min
interruption
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 Additional 25…50 kWh/t

20. Energy efficient Melt process –
Melting
 Using the melt processor to
get optimal power to the
material
 Always if possible:
 Close cover!
 An open cover adds (12 t
furnace)
 600 kW heat losses
 5 min with open cover
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 50 kWh additional losses
 Exhaust volume has to be
reduced at closed cover

21. Energy efficient Melt process –
Preparation of the melt
 Time is money!
 If possible,use auxiliary
equipment
 e.g. Slag grapper
 Online connection between
spectrometer and melt
processor
 Melt processor calculates
automatically the amount
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of additions
 Always if possible:
 Close cover!

22. Energy efficient Melt process –
Preparation of the Melt
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23. Energy efficient Melt process –
Preparation of the Melt
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24. Energy efficient Melt process –
Empting of the furnace
 Optimize the ladle size to
minimize heat losses
 No fire work at the furnace
during empting!
 Optimize the transport ladle
(size)
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25. Energy efficient Melt process –
Empting of the furnace
Environmental empting of furnace
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26. Energy efficient Melt process –
Results
State of the arte Inefficient melt
technology process
 Charge preparation 10 kWh/t 25 kWh/t
 Charging 10 kWh/t 30 kWh/t
 Melting 15 kWh/t 70 kWh/t
 Preparation of the melt 10 kWh/t 50 kWh/t
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 Empting of the furnace 5 kWh/t 15 kWh/t
 Additional process losses 50 kWh/t 190 kWh/t

27. Agenda
 Energy balance for melting iron
 Energy balance of a state of the art
Induction melting system
 State of the are melting system ABP
 Energy balance of a melting system
 Energy effective melt process
 Integration of the melt operation into
the total process
©ABP Customer day Bangkog, 30.03.2012 27
 Automatic pouring system АВР
 Pouring via OptiPour®
 Energy - Benchmark

28. Integration of the melt operation into the total
foundry process
 Tandem melting plant with variable power distribution
©ABP Customer day Bangkog, 30.03.2012 28

29. Pouring with OptiPour®
 Regulated pouring
 Aim: level of liquid metal in the cup
constant during whole pouring time
 Changing of pouring conditions in the cup
mainly based on opposite pressure inside
of the cup  should be reproducible from
cup to cup
 No big differences for stopper, nozzle and
level of liquid bath
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30. Pouring with OptiPour®
 Different systems for automatic pouring
 OptiPour® - C (with camera)
 Flask lines with big cup diameters
 OptiPour® - L (with laser)
 High speed molding lines with extreme small
cup diameter and measure nose for the laser
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 OptiPour® - LL (with Line-Laser)
 High speed molding lines with extreme small
cup diameter

31. Agenda
 Energy bilanz for melting iron
 Energy balance of a state of the art
Induction melting system
 State of the are melting system ABP
 Energy balance of a melting system
 Energy effective melt process
 Integration of the melt operation into
the total process
©ABP Customer day Bangkog, 30.03.2012 31
 Automatic pouring system АВР
 Pouring via OptiPour®
 Energy - Benchmark

32. Energy – Benchmark, foundries
Theoretically Equipment losses
Energy consumption
Process losses
Integration losses
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 Aim: specific energy consumption < 580 kWh/t

33. Energy – Benchmark, foundries
kWh/t
1.200
1.000
800 Melting - Pouring
Process
600 Equipment
Specific Enthalpie
©ABP Customer day Bangkog, 30.03.2012 33
400
200
0
State of the art Future destroyer
Old fashioned

34. ©ABP Customer day Bangkog, 30.03.2012 34
attention…
Thank you for your

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Contact:
ABP Induction Systems GmbH
Kanalstraße 25
44147 Dortmund
Jürgen Himmelmann Phone.: 02 31 / 997 – 28 88
Fax: 02 31 / 997 – 24 67
Mail: juergen.himmelmann@abpinduction.com